1988 PCX-954 Transport lift project

Old Tinkererer

I took some new pics with my cart back together. I'll ask for some help in a few days with the wiring puzzle, seems we disconnected some wires we didn't label and we're getting nothing now when we press the go pedal. Any experts out there on the 88 models?

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BGW

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LukeL

Never actually worked on one of those personally, but it must be similar to the marathons of the time. Is it a resistor setup?

JohnnieB

It's a resistor drive, but not the same as what's in a Marathon.

Attachment-1 = Marathon has 4 speeds and uses a wiper type switch to select the resistors.
Attachment-2 = PCX9xx has 3 speeds and uses solenoid's to select resistors.

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Old Tinkererer

JohnnieB, silly questron, could the resistor bank in the diagrams actually be the controller? I don't find a coiled up wire looking thing anywhere on this cart but it does have a Curtis P.M.C., DC motor controller on it, model PMC-5A.
Also I've only located one lone solenoid, a 4 terminal one that appears to actually have one of the large studs attached directly to the controller.
I won't be able to tinker with it for several days but would very much appreciate yoiur help, maybe walking me through solving this? You seem to have a solid working knowledge of carts and this one's system, specifically. I've looked over the ones you sent me but nothing seems to match exactly. I have no basic knowledge of how electric cart control circuits work together, thus my struggles. I know the POT shouldn't work without the key on, I THINK the POT sends current to the controller through the F&R switch? Right now the F&R has 3 or 4 wires hooked to nothing but a red w/wht stripe wire connected to same. This was the only wire that remained connected from the original configuration.
My fear is burning something up trying to solo this problem. Would you please consider me getting back with you in a few days for some one on one guidance?

Old Tinkererer

LukeL I'm not sure how to tell? I see a large coiled up item in some of the wiring diagrams that JohnnieB sent me but I don't see anything that looks like that on my cart. I'm familiare with what a 12v ballast resistor looks like since I have worked with them on automotive applications. I asked JohnnieB could the resistor bank and the Curtis controller be one and the same?
This cart ran fine, forward and rearward, batteries charged fine, lights worked - all was weel until we took the body off and some wires got disconnected before labeling so I feel it's something really simple in the wiring and not a hard component failure. Thanks for you help sir!

JohnnieB

The drive system is either a resistor type or a controller type.

Since I now know by your statements your cart has a controller, I'm fairly sure it was made later than 1988. Either that or somebody has converted a 1988 resistor drive to a controller drive, in which case no wiring diagram is likely to exist.

The attached schematic is for a PCX-9xx series controller drive and is probably as close as can be found for your cart.

Please post pictures of the controller and solenoid and batteries. Maybe the loose wiring can be figured out from them.

If this is a modified drive system, the color of the wires is iffy at best, so they will have to be traced to identify where they go to and from where they originate.

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Old Tinkererer

JohnnieB I think you may be right about the conversion & the wire colors not matching up.
i will post some pics as soon as I'm able, of everthing I have. Whatever they did during the conversion worked well, I had no problems before the project. Thanks again for your help with this.

Old Tinkererer

JohnnieB - I've got some pics to show you. Let's start with the harness coming out of the POT. The POT harness has 3 wires, red, black, white. They are attached to a 4 wire segment of the control harness on the cart as pictured. These two were labeled & disconnected prior to the tear down. I feel these are as they were before. The 3 white wires with colored stripes when traced, all connect to the controller. At the controller, the portion of the control harness that contains these 3 white w/colored stripe wires also has a single black wire that is not, and, was not attached to anything. Since all 3 white w/colored stripe wires attach to the controller, I'm second guessing myself that maybe the unattached white w/red stripe wire at the POT connection should possibly be attached to the black POT wire in place of the blue wire?

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Old Tinkererer

This pic I left out, it shows the portion of the control harness that contains three white w/colored stripe wires and a single unattached wire at the controller. Again these 3 wires attach to the POT harness as follows: POT red to harness white w/orange, POT white to harness white w/violet, POT black to harness blue - again I am second guessing myself as to the correct reconnection since the harness white w/red is not attached to anything?

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Old Tinkererer

My second dilemma is where to connect the wires coming out of the f/r selector. In the first pic below you see a single red wire w/white stripe coming from the reverse sside microswitch, this wire remained connected during tear down so I feel it is correct - it traces back to one of the small terminals on the solenoid. I suspect the yellow wire coming from the same microswitch has soemthing to do with back up lights? There is bundled and unconnected yellow wire nearby that was not attached to anything at any point since I've owned this cart. Then there's the blue wire coming from the opposite side of the same reverse microswitch - where to attach this one? The buzzer was removed by myself so those two wires reduce the maze a little bit. As for the red wire coming from the forward microswitch, same question, where does this one need to go? The second pic shows the control harness stem closest to the f/r switch, as you can see it contains red, blue, black, and purple wires. I would assume these attach to f/r switch red to red, blue to blue but not going to connect until I am more convinced.

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